Test circuit cables



Feb. 16, 1960 H. F. DALGLISH 2,924,974

TEST CIRCUIT CABLES Filed Feb. 9, 1954 s sheets-sheet 1 BY m.

ATTORNEY INVENTGR Feb. 16, 1960 Filed Feb. 9. 1954 H. F. DALGLISH TEST CIRCUIT CABLES 3 Sheets-Sheet 2 MAX. A3/.E 4LEA/6TH Edf/0 ATTORNEY INVENTOR Feb. 16, 1960 H. F. DALGLlsH 2,924,974

TEST CIRCUIT CABLES Filed Feb. 9, 1954 3 Sheets-Sheet 3 F' .l 4 l l /7 INVE ATTORNEY United States Patent 2,924,974 TEST CIRCUIT CABLES Herbert F. Dalglish, St. Paul, Minn. Application February 9, 1954, Serial No. 409,239 s Claims. (C1. 734-341) This invention relates to an improvement in test circuits and deals particularly with a flexible cable device for measuring temperature at various distances from one or both ends of the cable.

In thestorage of various hydrocarbon materials, it is desirable to maintain a check upon the temperature conditions at various points within or about the material stored. For example, in the storage of grain, it is common practice to store this material in elevators which are of considerable height. Varying temperature conditions in the grain are of importance as when the grain reaches a certain temperature, spoilage from one source or another is apt to occur. In the storage of cotton, waste paper, coal or other materials, changes in temperature at various points of the materials stored is indicative of internal combustion or some condition which may be extremely dangerous to the material or to the quality thereof. The present invention relates to a device capable of measuring suchtemperatures.`

Various devices have been provided designed to measure temperature at various elevations in a bin of grain orsimilar material. In general, these devices have been of two types. Most such devices have been in the nature of thermocouple or thermopile circuits contained within a conduit or pipe. Other such circuits have been contained in a plastic sheath made of nylon.

The object of the present invention is to provide a temperature measuring apparatus which includes a thermocouple orthermopile circuit enclosed within a wire rope. Such a structure has numerous advantages over anything which has been previously devised. In the first place, the wire rope is porous to the extent that the core of `the rope which contains the circuits is in more intimate contact with the ambient air. Thus, changes in `temperature are much more quickly and readily indi- "catedby the enclosed circuit. Furthermore, such a device has the strength to be self-sustaining and is, there- `fore, `much `stronger `than previous .devices and, accordingly, much less injurious `to the circuits enclosed. `The-use of a `wire rope containing, as a core, thermo- `couple or` thermopile circuits has numerous advantages dependingupon the type ofmaterial with which they Aareused. A cable ofrthe typeV described may be suspended from the top of an elevator and will withstand wear and external forces much better than the rigid pipe or`conduitusually employed. When the grain is inserted into, or removedfrom, the elevator, it exerts `a considerable force against any fast or rigid object, due to the swirling movement of the material. A wire rope cable may flex to follow the movement of the `grain While a rigid fixed pipe cannot. As a result, considerably less strain is exerted upon the present device than is applied against rigid pipes which have been previously used for a similar purpose.

When `used for other hydrocarbon materials including in addition to the previously mentioned materials, wood, peanuts, various maste materials and feed, the flexibility and strengthpof the cable is alsootimportance. A wired rope cable may beextended through a pile of waste paper in bales or bundles without ill effects, While a rigid conduit would be quickly broken or bent under similar conditions. For this reason, the use of the circuits in a wire rope is of importance.

`A further feature of the present invention resides in the fact that the wire rope cable employing the thermocouple or thermopile circuits is ordinarily less expensive to install than previous devices, and yet is more sensitive and more `accurate due to the fact that lthe ambient air is allowed to penetrate the outer surface of the cable. At the same time, the structure is stronger than previous arrangements and requiresconsiderably `less space.

An added feature of the present invention resides in the provision of a thermocouple or thermopile circuit v which may be formed continuously and in which indications may be provided at substantially equal distances throughout the length of the cable. The core of the Wire rope cable is formed by using a common wire of one metal and a series of Wires Vof a dilerent metal, which extend longitudinally of the core. Each of the wires encircling or extending longitudinally of the common Wire is connected tothe common wire at substantially equally spaced points throughout the lengthl of the common wire. As a result, theV core` is capable of measuring temperatures at substantiallyequal intervals throughout a length of upto approximately twice the distance between the points of connection of each wire with the common wire. i

It has been found that if` wire of one material is secured to a common wire of another material at two spaced points, temperature measurements may be made from locations beyond these spaced points at opposite ends of the `wire and common wire to determine ternperature conditions at the above mentioned two spaced points. VThis principle is employed in the production of a temperaturepmeas'urement cable of a continuous nature. If the cable contains twenty insulated thermocouple wires of one material, each of which is conductively connected to a common wire of another material at intervals of one hundred feet, and the insulated wires are conductively connected to the common Wire at intervals of tive feet apart, the .temperature may be measured at intervals of live feet throughout the length of a cable up to one hundred ninety-nine feet plus in length. This may be accomplished by taking measurements from both ends of the cable.

An added feature of the present invention resides in the provision of a wire rope having as its core a thermocouple or thermopile network which may, if desired, be enclosed in a wrapping containing a series of conductors. These conductors may be used for connecting the thermocouple `wires at one end of the cable to the other end thereof.

In description of the features, and in the following description of the drawings, the thermoeouples have been described as located at substantially equally spaced points. It is believed obvious that, while it is usually most desirable to equally space the thermocouples, this is not essential, and the spacing may be unequal if preferred to suit special requirements. The description also relates to a single common Wire, but under some conditions it is preferable to employ a plurality of common wires instead of the single common wire mentioned.

In describing the device as comprising a wire rope having a series of thermocouple circuits in its core, it is not desired to limit the nature of the outer portion of Vthe rope to any particular form or arrangement. In other words, the metallic Wires which enclose thev core These .and other objects and novel features of the invention will be more clearly and fully set forth inthe following specification and claims.

:In thezdrawings'fforming a .part of the present invention: p' i Figure l'is a cross sectional viewthrough a wire rope or cable indicating `the manner in whichithe present invention may be accomplished.

Figure Zis'la diagrammatic Aview showing the'wiring of the cable in its more complicated form.

'Figure 3 :isV a diagrammatic kView showing the manner in which the'cable core may be wrapped so'that readings from both ends .of the cable may. be obtained from a single end thereof.'

Figure f4`is a diagrammaticview showing the manner in which the' lsingle wires vrnay be secured to the main Figure 5shows` the manner in which the circuit wires may ybe wrapped'with the tirst wrapping.

Figure 6 is ra'view showing the manner in whicha second sheath 'may be applied over the first covering.

Figure 7 shows the manner in which a third wrapping may be applied about thev second wrapping to improve Vthe insulation qualities 'of the core.

Figure 8 shows a wrapping which may be applied overY the .previously described coverings.

Figure 9.is Ia cross sectional view through a wire rope similar to that previously described but in which a plastic coveringfis appliedover .the circuit wires.

Figure .10 isa diagrammatic view rof an alternate construction.

A typical cross sectional view of the cable described in the Apresent inventionis shown at A in Figure 1 of the drawings. This Yview 'shows' acore, illustrated in general by "the numeral 10, `encircling the individual lwiresof the core. About the periphery of vthe core 10 is a coating of finsulating vmaterial,y shown in general by thefnumeralll. 'About'the periphery of the insulation 111isv a wirerope, illustrated in general by the numeral`12. It is'they circuit bearing core 10, the insulation layer 11,v and` thewire rope covering 12, which "form the basis fof the present invention, although there are other Yfeatures which 'are also of advantage.

' The wire core is'preferably formed as best illustrated v'in Figures 2 and 4 of the drawings. Figure 4 disclosed a common -wire 13 'of one Vmetallic material such as that lcommonly known as constantan. The remaining wires,

Ywhich are connected to the common wires at substantially equal or predetermined intervals is of another metallic material, such as that known as Formvar vor Formex type insulated copper. These wires have been jpreviously used in forming thermocouples or thermopiles, and are'not 'a part of the present invention. Other 'combinations of metallic wires maybe substituted, together with their advantages and disadvantages.

As shown in Figure 4'of the drawings, a wire of one material such as 14 is connected to the common wire 13 vto extend in both directions from the pointjof connection. LIt is believed obvious that the connection 15 between the wire 14- and the common wire 13 lforms a thermocouple which may be read from either end-of `the wires Y1% kand 14. The next wire 16 is yconnected to the common wire 13 at apoint 17 spaced along the common wire from the point of connection 15 substantially Aa'predetern'iined distance. The next wire 1 9 is connected to `the common wire 13 at a substantially equal distancev along the `common wire to the distance betweenthe points of connection 15 and 17. In a similar manner, any desired number of wires may be connected to the common wire along the length thereof,

the points of connection being at predetermined intervals..

Each wire preferably extends the full length of the common wire '13, vso that the temperature lconditions at any point 'along the length ofthe common wire maybe measured from either end of the cable.

In the preferred form of this invention, the common wire is connected to the cooperable wires of different metallic material at predetermined intervals. In other words, alll of the wires extend the full length of the cable. If the first or common wire is defined as `the common or primary wire, the wires of other material forming the thermocouples orthermopiles may be described as the secondary wires. The number of thermocouples in the finished structure depends upon the number of times the secondary wires embodied in the core are connected to the primary wire. If the core is considered to have a single primary wire land twenty secondary wires, obviously there may be twentythermocouples in the cable core if each is connected once. Each of the secondary wires is connected to the common wire at predetermined distances. For example, in the core having twenty secondary wires, each secondary wire may be connected to the common-wire at intervals 'of onehundred feet, and if the secondary wires are connected to the common wire-at intervals of iive feet, a

' tive ,foot intervals throughout a cable of substantially two vhundred .feet in length, ifk readings are taken from both :ends ofithe'cable. This is not an obvious conclusion, but one which has vbeen discovered.

Withgreference to Figure l2 rof the drawings, thecable is diagrammatically illustrated at-A. Alength of cable vis shown which is Vtwice the length ofthe-distances between the'points of connection between the secondary wires and the primary wires. During this length of wire rope, each secondary wire is connected 'to the common wire twice. A first wire 20 is rconnected to the .common wire 21 at points 22 and 23, which may beffor example,

-one hundred feet apart. The vfirst connection lis five feet `from theV upper end 24 of the circuitry, while the second connection is one hundred feet therefrom,- or ninety-five -feet from the lower end 25 of the structure. By measuring from the'upperend of the cable, a temperaturevreading at an elevation of tive feet from the end 24 of theV circuitV may be obtained, and by measuring from the other end 25 of the circuit, a temperature reading at the Y point 231,` ninety-iive feet from the end 25 may ber obtained. t

Similarly, the second wire 26 is connected to the common wire 21 at a point 27 ten feet from thecircuit end 24 and ata point 29 one hundred ten feet from the end 24, or ninety feet from the rope end 25,. As a result, temperatures may be read at each point 27 :and 29, one reading being obtained from one end of the network and the Vother reading being obtainedl from the end thereof. .The fact that the two points kof connection are also connected does not change the results obtained materially, as the thermocouple reading at either Aendrof the cable isobtained'between the endk of the'circuitry `and thernearest'junction of any secondary wire with the eral description. Each of the secondary wires'islconnected v to the common Wire at substantially equal intervals, and

the vdistance between the points of connection-of the sec` ondary wires and the common wire is also substantially equal. In the particular'construction described,readings fin-the upper portionof'the cablevmaybenbtained/atiniervals of live feet from the upperend 24 ofthe circuit, and readings in the lower portion of the circuit 'may be 'obtained at intervals of tive feetfrom the lower end 25 of the circuit. In'describing such ,an arrangement, the lterm upper used in conjunction with the circuit and dentiled by the numeral 24as well asthe term lower Iused with the numeral 25, merely describe locations on the drawings where oneof them is aboveithe other; in actual .'practice, the finished structure may be horizontal or inclined, as well as'vertical.` f i V As also shown in Figure 2 of the drawings, each end of the circuit may be connected to an apparatus for indicating temperatures at the various junctures of the common wire and the secondary wires. A rotary switch 31 is connected to the secondary wires at the end 24` of the-circuitry and a second rotary switch 32 is connected to the other -end 25 thereof. The wires are connected in the obvious manner to contact points about the periphery of the switch, while the rotary arm 33, ofswitch 31,-is connected through the selector switch 34, to the galvanometer or other indicating device 35; the'other terminal of which is connected to the common wire 21. The selector switch 3'4 selects the switch to be connected to the galvanometer, and the rotary arm of either the described switch 31, or to the companion rotary switch 32 having a rotary arm 37. In the particular construction described, the temperature may be determined at intervals of live feet throughout the length of practically two hundred feet. Obviously, these figures are stated only as an example, and the intervals between connections of the common wire, or wires, with the secondary wires, as well as the number of secondary wires and common wires employed, may be varied considerably depending upon the requirements of any particular job.

In the formation of the wire rope test cable A the core may be formed continuously by extending the number of wires employed throughout the length of the wire rope and connecting each individual wire to the common wire at equal intervals. The core thus formed may be coated with a plastic coating to insulate the core from the wire rope. This may be done in various ways. In Figure 1 of the drawings the core .is covered with a series of layers of insulation indicated by the numerals 39 and 40 and the core may then be wrapped with a sheet of insulation 41 having a series of spaced wire conductors 42 extending throughout the length thereof. These wires 42 may be embodied in a flat ribbon of insulation of the type commonly used for TV aerial lead-in wire or the like. This ribbon may be wrapped about the core in the manner of Figure 3 of the drawings so that the wires 42 are spaced about the periphery of the core. The wires 42 may be equal in number to the wires forming the thermocouple or thermopile circuits within the core. If desired the ribbon N41 may be covered with a layer of insulation 43 and the -core is then encircled by the wire rope strands 12, each of which is composed of a plurality of wires.

The purpose of the ribbon or tape 41 and the wires 42 "is to provide a means of connecting the circuit wires at -one end of the wire rope to the other end thereof. In other words, in the example previously described, if the A.test cable is more than one hundred feet in length, the conductors 42 may be used to connect the thermocouple 'wires at one end of the cable to instruments at the other Aend of the cable. Thus, the lower end of the cable need not be tied down, when lused vertically, or separate conductors need not be connected to the lower end of the cable to provide readings of temperature in the second one hundred feet of cable.

This arrangement has the advantage that instruments may be provided at one end only of the cable even though the cable be in excess of one hundred feet in length. Here again, it must be remembered that the one hundred feet mentioned in the example is only for the purpose of illustration.

In a modied form of construction the core may be covered by a coating ,ofplastic,.or the like, which may be sprayed or extrudedonto the surface of t`l1e core, maybe applied by dipping the core through the coating solution or may be applied in any other manner. If a proper coating is applied, the core may be formed into the wire rope and `the circuit `wires maybe. insulated from the metal covering. i 1 l In Figures 5 through 8 Vof the drawings, I disclose a modified form of ,construction in which the core is provided with a series of'insulation coverings. In the arrangement shown in Figure 5, a paper tape 44 may be wrapped spirally about the core which is indicated in general by the numeral 45. Apaper tape 46 may then .be folded aroundthe wrapped corein Figure 6. A plastic tape 47 may then be wrapped about the paper tape wrapping 46 as shown in Figure A7. The product of Figure 7 is then spirally wrappedwith a tape 49 possessing electrical insulation properties. `This `product may be used or may be further coated or processed. i

The wire rope cable thus `formed has numerous advantages from a construction and use standpoint. The test cable thus formed is readily flexible and may be suspended in a bin or tank of grain or Jextended through piles of material for use in indicatingr temperature at various points along the cable. When used in a grain elevator the cable will last considerably longer than test circuits enclosed in rigid pipes due tothe fact that the cable may flex with the flow of the grain thusdecreasing the abrasive action and resistance pull of the grain. The cable is not subjected tothe same twisting forces which will be found in rigid `conduits, because of this property-of the cable to ilex upon being subjected to pressure. Furthermore, the cable is of relatively small diameter as compared with rigid conduits as previously used. Five-sixteenth inch, three-eighths, or one-half inch diameter wire rope cable may be effectively used for the purpose in place of a rigid conduit of perhaps three-quarter inch width with joints one and one-half inch in outside diameter.

If it is preferred the outer cable 50 may be used as the common wire of the circuits. Such an arrangement, illustrated in Figure l0, has the advantage that the junctions 51 between the individual secondary wires 52 and the primary common wire are exposed to ambient aair. Due to the fact that all of the strands of the wire rope are in intimate contact, they comprise a single conductor, and the junctions may be formed with any of the strands of the wire rope. The arrangement has the disadvantage that it is somewhat less eicient than thermocouples constructed of constantan and copper, and also that under present methods of construction it is somewhat more diicult to construct. However, when the cable is made in this manner it will function effectively and produce temperature measurements.

Again it should be stressed that the particular arrangement of the metallic wires of the cable is not important and that these wires may be laid twisted or braided as long as they provide the covering sheath which provides the necessary tensile strength and resistance to abrasion.

Not only is the present cable structure the strongest'on the market but it is also the most sensitive and accurate due to the nature of the construction. The plastics and insulation materials employed are much better conductors of heat than is the nylon used for covering thermocouple circuits which have been previously constructed. In other words the nylon covered circuits previously used had to be made of a plastic which was strong enough to withstand the forces exerted upon it and as a result the plastics had to be thick and of material possessing high heat insulation properties. In the present arrangement the wire cable merely supports the core and the covering of the core is only to insulate the wires from the outer wires forming the rope.

In accordance with the patent statutes, the principles of construction and operation of the test circuit cables have been described and while it has been endeavored to fof 'onematerialdatserieseof conductive -Wires of Ya second material, each fsaid AWires 'offtheseries being connected tovsaidycommon wire -at substantially equally llongitudinal-ly spaced points, each of the -wiresfof `the seri'es"being connectedat a second point to 1 the 'common Vwire Ybetwe'en each yof the spaced Jpointsof `first' connec- Ttionbetweenv any "one Wireof the series and said common wire, the points-'ofconection'beingsubstantially equally 'spaced `along"the` common lwire, and meansconnected to each *end of said= series vof wires and Vsaid common wire for reading temperature-at the nearestjunction of ,each wire' of the Yser'iesfandfsad' ycoinrnon'fwire.

2. The structure 'described in claim 1 and including a :series ofl'auxiliaryinsulate'd conductors forming al part of the core, veachI connected to ya corresponding wire 'of `said` series atxanlen'd thereof.

3. The structure "defined 'in claim 1 'and including a sheath encircling saidcoreandincluding a series of auxiliary vinsulated conductors in electrically insulated relation, each connectedto a corresponding wire ol-saidv ser-ies at anend thereof.

4. A thermocouple stx'ucture'in'cluding a series of wires Iof one materialf-a'- common -wire of f different material,l a

8 junction between "each wire of the f series and -fthe *comi mon-Wire, V-thewires ofthe series being connectedfiin orderlandthe junctions being substantiallyequall spaced, a second junction between each o'f-f'tlie Awireslof J'thei-seri and the cornmonwire inthe-same order as-mentioned above,- aridmeans connected to each endfofI saidseriesof Wires 'andi said common Wire for "reading rtemperature .at the-nearest junction-of'each wire :of thefseries andsaid commonlwi're.

5. A thermocouple structure includingra 'seriesoflwiree of 'one material, a-common wire of'adiiferent material, a :junction 7'bet-Ween each-Wire of J the series,-.vand` the common i4Wire, the wires ofthe series fbeingconnected in torder and the junctions `being substantially equally spaced',fase'cond yjunctionV between'atleast some :of .the Y wires of the-series :andfthe common 'Wirefinthefsame order as mentioned i above, 'andv means .connected fone end 'of saidseries of wires-andlsaid rcommon-:wireVand to 'the other end of "each lwirehaving arsecond'junction and they other end-of saidcommon wirefor reading-temi- 'peratu're 'Yat "thenearest -jumition of afeach-wireof series and-said common wire. v

.Referencesl Cited inthevleof this patent UNITED STATES v1 ATI-31-ITS v z2,665,322 .MacDonald ;Jan.5, 1.9.54

,FOREIGNPATENTS'r 692,641 :Germany June24;194

674,068 fGreat' Britain lune 18,;,1352 

